DPA automated assembly and packaging machine

Abstract

This patent relates to a machine that automatically assembles, inspects, and packages disposable prophylaxis angles. The machine includes a movable table including a plurality of fixtures on which angle components are assembled and the assembled angles are inspected. The movable table is surrounded by a number of stations, each of which performs a different operation of the assembly and inspection procedure. Feeders automatically supply the angle components to their respective stations for assembly. Angles that are incorrectly assembled are automatically rejected. Properly assembled angles are automatically sealed in individual bags. Individually bagged angles are counted into batches by the machine and automatically sealed into cartons.

1. A method of assembling a dental product, the dental product having a body, a first gear member, and a second gear member, the body including a portion attachable to a dental handpiece, a closure attached to the body by a hinge, and at least one latch for securing the closure to the body, the method comprising:
 taking and orienting a body of a dental product to receive a first gear member; 
 placing the body in a fixture in an orientation where at least a portion of a hinge of the body is located higher than at least a portion of the portion of the body attachable to a dental handpiece and where at least a portion of the closure is adjacent a rotatable member operable to engage the closure and latch the closure to the body; 
 transferring the first gear member to the body at the fixture; and 
 supporting the body and the first gear member of the dental product on the fixture as the dental product is being assembled. 
 
     
     
       2. The method of  claim 1 , further comprising receiving and holding the body of the dental product at the fixture by the portion of the body attachable to a dental handpiece. 
     
     
       3. A method of assembling a dental product, the dental product having a body, a first gear member, and a second gear member, the body including a portion attachable to a dental handpiece, a closure attached to the body by a hinge, and at least one latch for securing the closure to the body, the method comprising:
 taking and orienting a body of a dental product to receive a first gear member; and 
 placing the body in a fixture in an orientation where at least a portion of a hinge of the body is located higher than at least a portion of the portion of the body attachable to a dental handpiece; 
 wherein the body is placed in a fixture at a body station, which body station is one of a plurality of stations; and/or 
 wherein the method further comprises at a plurality of fixtures, supporting the body, the first gear member, and the second gear member of a dental product on each fixture as the dental product is being assembled, and moving the fixtures past the plurality of stations at which different assembly steps are performed. 
 
     
     
       4. A method of assembling a dental product with an automated assembly machine, the dental product having a body, a first gear member, and a second gear member, the body including a portion attachable to a dental handpiece, and a hinged closure attached to the body, the method comprising:
 providing a plurality of dissimilarly oriented bodies; 
 positioning multiple ones of the bodies in similar orientations in a track; 
 suspending the similarly oriented multiple bodies from the track by the hinged closure of each body; 
 moving the similarly oriented multiple bodies along the track; 
 isolating a single body from the multiple bodies in the track by raising a single body from the track; 
 holding the isolated body from the track for transfer to a fixture for holding the dental product during assembly; and 
 transferring the isolated body to the fixture. 
 
     
     
       5. The method of  claim 4 , further comprising raising and holding the isolated body of the dental product from the track by the portion of the body attachable to a dental handpiece. 
     
     
       6. The method of  claim 4 , further comprising receiving and holding the isolated body of the dental product at the fixture during assembly by the portion of the body attachable to a dental handpiece. 
     
     
       7. The method of  claim 4 :
 wherein the oriented bodies are parallel to each other and side by side in the track; and/or 
 wherein the bodies are positioned in a track of a body station, which is one of a plurality of stations; and/or 
 wherein the method includes at a plurality of fixtures, supporting the body, the first gear member, and the second gear member of a dental product on each fixture as the dental product is being assembled, and moving the fixtures past the plurality of stations at which different assembly steps are performed. 
 
     
     
       8. A method of assembling a dental product, the dental product having a body, a first gear member having a gear end and a shaft end, and a second gear member, the method comprising:
 receiving and holding a body of the dental product at a fixture during assembly; 
 providing a plurality of dissimilarly oriented first gear members; 
 positioning multiple ones of the first gear members in similar orientations in a track; 
 suspending the similarly oriented multiple first gear members by the gear end of each first gear member from the track; 
 moving the similarly oriented multiple first gear members along the track; 
 isolating a first gear member from the multiple first gear members in the track by raising a single first gear member from the track; 
 holding the isolated first gear member from the track for transfer to the body in the fixture; and 
 transferring the isolated first gear member to the body in the fixture. 
 
     
     
       9. The method of  claim 8 , wherein the first gear member is positioned within the body in an orientation where the gear end is located higher than the shaft end. 
     
     
       10. The method of  claim 8 , wherein the first gear member is inserted into the body shaft end first. 
     
     
       11. The method of  claim 8 :
 wherein isolating a first gear member includes engaging the shaft end of the first gear member to raise the first gear member from the track; and/or 
 wherein the similarly oriented multiple first gear members are oriented and fed along the track in pairs diameter to diameter; and/or 
 wherein the first gear members are positioned in a track of a first gear member, which is one of a plurality of stations; and/or 
 wherein the method includes at a plurality of fixtures, supporting the body, the first gear member, and the second gear member of a dental product on each fixture as the dental product is being assembled, and moving the fixtures past the plurality of stations at which different assembly steps are performed. 
 
     
     
       12. A method of assembling a dental product, the dental product having a body, a first gear member, and a second gear member having a flange, the method comprising:
 at a fixture, receiving and holding a body and a first gear member of the dental product during assembly; 
 providing a plurality of dissimilarly oriented second gear members; 
 positioning multiple ones of the second gear members in similar orientations in a track; 
 suspending the similarly oriented multiple second gear members by the flange of each second gear member from the track; 
 moving the similarly oriented multiple second gear members along the track; 
 isolating a second gear member from the multiple second gear members in the track by moving a single second gear member from the track; 
 holding the isolated second gear member from the track for transfer to the body at the fixture; and 
 transferring the isolated second gear member to the body at the fixture. 
 
     
     
       13. The method of  claim 12 :
 wherein isolating a second gear member includes engaging the flange of the second gear member to raise the second gear member from the track; and/or 
 wherein the similarly oriented multiple second gear members are oriented and fed along the track diameter to diameter; and/or 
 wherein the second gear members are positioned in a track of a second gear member station, which is one of a plurality of stations; and/or 
 wherein the method includes at a plurality of fixtures, supporting the body, the first gear member, and the second gear member of a dental product on each fixture as the dental product is being assembled, and moving the fixtures past the plurality of stations at which different assembly steps are performed. 
 
     
     
       14. A method of assembling a dental product, the dental product having a body, a first gear member, a second gear member, and a tool having a base end attachable to a second gear member, the method comprising:
 at a fixture, receiving and holding a body, a first gear member, and a second gear member of the dental product during assembly; 
 providing a plurality of dissimilarly oriented tools; 
 positioning multiple ones of the tools in similar orientations in a track; 
 supporting the similarly oriented tools by a base end of each tool from the track; 
 moving the similarly oriented multiple tools along the track; 
 isolating a single tool from the multiple tools in the track by moving a single tool from the track; 
 holding the isolated tool from the track for transfer to the body at the fixture; and 
 transferring the isolated tool to the body at the fixture. 
 
     
     
       15. The method of  claim 14 :
 wherein the similarly oriented multiple tools are oriented and fed along the track diameter-to-diameter, axis vertical, large diameter down; and 
 wherein the tools are positioned in a track of a tool station, which is one of a plurality of stations; and/or 
 wherein the method includes at a plurality of fixtures, supporting the body, the first gear member, and the second gear member of a dental product on each fixture as the dental product is being assembled, and moving the fixtures past the plurality of stations at which different assembly steps are performed. 
 
     
     
       16. A method of assembly a dental product, the dental product including a body and a first gear member having a gear end and a shaft end, the body including a portion attachable to a dental handpiece, a portion that receives the first gear member, and a closure attached to the body by a hinge, the method comprising:
 receiving and holding the body at a corresponding fixture; 
 positioning the closure of the body adjacent a support section of the corresponding fixture such that the body is received and held at the corresponding fixture in an orientation to receive the first gear member and at least a portion of the closure is adjacent a rotatable member operable to engage the closure and latch the closure to the body and such that at least a portion of the hinge is located higher than at least a portion of the portion of the body attachable to a dental handpiece; and 
 transferring the first gear member to the body at the fixture, whereby the first gear member is positioned within the body in an orientation where the gear end is located higher than the shaft end. 
 
     
     
       17. The method of  claim 16 , further comprising receiving and holding the body by the portion of the body attachable to the dental handpiece. 
     
     
       18. A method of assembling a dental product, the dental product including a body having a closure attached by a hinge and at least one latch, and first and second gear members, the method comprising:
 at a plurality of fixtures, supporting a body, a first gear member, and a second gear member of a dental product on each fixture as the dental product is being assembled; 
 locating a hinged closure of the body of each supported dental product adjacent a rotatable member of the fixture supporting the respective dental product; 
 moving an actuator into engagement with at least one of the plurality of fixtures such that the actuator rotates the rotatable member of the at least one of the plurality of fixtures causing the rotatable member to rotate, contact the hinged closure of the dental product supported by the at least one of the plurality of fixtures, and rotate and latch the hinged closure to encapsulate the first and second gear members in the body. 
 
     
     
       19. The method of  claim 18 , further comprising moving the fixtures past a plurality of stations at which different assembly steps are performed.